Method oe making abticles from steel ingots



April 20 1926.

R. G. COATES METHOD 0F MAKING ARTICLES FROM STEEL INGoTs Filed August 25, 19.20 2 Sheets-Sheet l Jullllnhm wwntoz @M wm muy 2 Sheets-Sheet 2 vwwntoz Ap'fr zo, w26.

R. G. coATEs METHOD OF MAKING ARTICLES FROM STEEL INGOTS Filed August @5% www* M Patented Apr. 20,1926.

UNITED STATES 1,581,512 PATENT oEFIcE.

'RAY G'. COATES, OF PASADENA, CALIFORNIA,

ASSIGNOR, BY MESNE ASSIGNMENTS, OI'

ONE-HALF T0 THE ESTATE OF H. G. HAMILTON DECEASED, LATE OF YOUNGSTOWN,

OHIO.

METHOD OF MAKING ARTICLES FROM STEEL IN GOTS.

Application mea August 25, 19:20@ serial no, 405,97'6.

To all whom t may concern.'

Be it known that I, RAY G. CoA'rEs, a citi- Zen of the United States, and a resident of the city of Pasadena, in the county of Los Angeles, State of California, have invented new and useful Improvements in Methods of Making Articles from Steel Ingots, of which the following is a specification.

This invention relates broadly to metallurgy and more particularly to the method of treating steel ingots in making articles of manufacture, and the article resulting from the treatment.

The principal object of the present invention is the method of treating a steel ingot to elongate the'same while maintaining the upper portion of the ingot in a definite part of the elongated mass and then severing such.v

upper portion as scrap. t

A still further and important object of the present invention is the method of fabricating articles from a steel ingot which comprises rolling or forging the article to a shape approximating the final form and maintaining the metal from the top portion of the ingot in an extended protuberance or fin which may be eut away as scrap.

A still further and important object of the present invention is the method of fabricating steel articles which comprises producing an elongated ingot having cupped zones of iso-crystallization extending toward one side of the ingot, forging or rolling the ingot to maintain such cupped zones cross- It is realized that the present invention may be carried out by'departing fromthe specific description herein but without departing from the spirit of the invention so therefore it is to be understood that the descriptive matter' herewith is to be considered i as illustrative and not in the limiting sense. Figure 1 is a diagrammatic' view illustrating an elongated ingot which has been cast in an elongated mold and showing an end View thereof with crystallization zones diagrammatically indicated by dotted lines.

Figure 2 is a view illustrating the side of the ingot shown in Figure 1;

Figure 3- 's an end vieW of the ingot shown in Figure 1 after it has been'rolled onV four sides, and illustrating the rough top as being ,one side;

Figure 4 illustrates further rolling of the ingot to form a slab and showing the rough top maintainedat the edge;

Figure 5 illustrates the shaping of the ingot to form a bloom with therough top in a marginal part of one side; l

Figure 6 is a view similar to Figure 5 showing the bloom further developed with the marginal top isolatedY at one side.

Figure 7 is a plan view of a slab with the rough top onone edge; Fi ure 8 illustrates a further rolling of the s ab;

Figure 9 illustrates cutting the rough edge from a sheet;

mediate step in rolling an 4I-beam shape and illustrating the zone of crystallizatlon by dotted lines and showing the rough top rolled into a protuberance or 1in;

Figure 11 is a view similar to Fig. 10

showingan intermediate shape for channell bar;

Figure 12 is a view similar to Figure 11 and showing a different shape; for example, a continental rail;

Figure 13 illustrates the method of cutting a bloom to take advantage of segrega-v tion' Figure 14 illustrates a bloom or slab cut in 'accordance with the lines indicated in Figure 13.

Heretofore in the art -it has been cus-. tomary to cast ingots in vertical molds and eut off the top portion thereof and then treat the remaining portion by rolling or hammering without respect to the relatlon yof 'any part of the ingot bears to the part of the fabricated article. In view of the fac-t that an ingot cast in a vertical mold separa-tes or segregates. on zones which are concentrlcally f the zo zones,

symmetric relative to the axis of the mold it lfollows that the upper end of the ingot contains more metalloid content than the lower end and the fabricated articles made from such an ingot are not uniform in metal content at the cross sections taken at opposit ends of. a long piece, like a railroad rai i The present method provides for fabricating articles of manufacture withreference to nes of crystallization in the steel so that` cross-sections through the fabricated articles will be substantially uniform as to metal content, throughout the length of the article. While the invention may be practised with various types of ingots, it is particularly adaptable to ingots cast horizontally with one long side forming the top of the ingot. In casting this type of ingot it is frequently'diiiicult to prevent wild metal from raising the top ofthe ingot, which produces a rough surface which is hard to reduce to a satisfactorily nished surface under the rolls. In accordanceA with the present invention the ingot is rolled or hammered in such manner that the part containing the rough top will become some prearranged marginal part of the intermediate or finished product so that this prearranged marginal part may be sheared of or cut 0E from the shape so as to leave the finished shape as desired and of goed clear metal. In

rolhng ingots in accordance with this method it is necessary to keep track/of the top surface or deleterious metal of the ingot until-the bloom, slab, or other shape has been so formed as to make the position of the rough top part thereof easily identified and isolated so that it maybe cut off by longitudinal shearing rollers or by special shears, by trimming the intermediate shape, or by trimming the plates after the slabs have been rolled into plates or otherwise. The longitudinal shearing preferably is done while the metal is hot and before the final passes through the rollers so that the final passes or run may smooth up the cut and leave faces.

Ingots which are 4cast longitudinally permit the metal to slightly segregate in cupped zones while the metal is cooling. There appears to be a tendency forthe metalloids such as sulphur, phosphorus, carbon' etc., to be expelled in certain proportions fro-m the steel as it cools. In view of the fact that the steel' cools from the bottom and sides ofthe chill mold in the form of cupped which cups contain the molten steel that has not as yet chilled, the freed metalloids accumulate in the metal last to freeze. Therefore the upper portion of such elongated in ot contains anincreasi'ng percentage of t ese elements as the top surface is approached. In view of thefact these' elethe sidesof the shape with good surments are lighter than the metal, gravity also has a tendency to cause. these elements to rise in themetal.. Furthermore, pure iron chills or freezes at a higher temperature than iron containing carbon so consequently the ortion containin the least amount of carbon tends to chill rst and the efct of the chill is to push a little more carbon into ,the liquid part left. This action reduces the fusion point and lowers the crystallization point since the action is traveling away from the solidifying metal, and as the metal continues to freeze the action lpro-- gresses so that segregation gradually takes plae from the bottom sid'e of the ingot to the top side thereof. It appears to happen that the segregation of the carbon, sulphur and hosphorous go along together probably ecause they actin accordance with similar laws rather than the effect of one vupon the other. This action tends to reduce piping in the elongated type of the ingots and produces zones of different saturation as to these materials as zones of segregation in the ingot whereby by cutting the ingot with reference to these zonesl di erent characters of steel maybe obtained.

Referring to the. drawings, 2 illustrate end and Side views respectively 1 of an alon ated ingot l which is formed with five chill 'sidesand with the top side nonchilled. Since the top side is the side through which gases have escaped from the ingot while it is cooling it sometimes happens that the top side is rough as at 2. In this type of ingot blended cupped zones A of iso-crystallization are formed. These zones are ordinarily not definitely dened but if the crystallization or freezing of the ingot where stopped at intervals 'and the molten metal vpoured out the remaining frozen portion would be of Athe form indicated by the dotted lines. .It will be noted that the shape of the cups gradually flattens toward the top of the surface and therefore it follows that the major selective portions of the zones are defined by the bottoms of the cups so that mechanical separation may be resorted to, to divide out any desired portionof the metal. v

Figures 3 and 4. illustrate end views of blooms or -slabs 4 and 5 in which the rough surface is worked to one side; In Figures 5 and 6 which represent end views of,.tl peblooms, the rough tops 6 and 7 are worked iii-to marginal portions adapted tlbe cut away as on lines B and C. Figures 7, 8 and 9 indicate plan views of slabs being rolled into plates and illustrating the rough tops 10 .on one edge of the plates 'and being adapted to be cut away as scrap on the line D of Figure 9.

Figures 10, 11 and 12 il ustrate sha es 12, 14, 15 rolled with protuberances or ns''l,

in which protuberances the rough top surlFigures 1 and mme percentages of steel and metalloids, etc,

which are wanted for the fabrication of particular articles.

By referring to Figures 10, 11 and l2 it` will be noted that the zones A are rolled into the shapes in such manner as to extend transversely of the shapes with the open sides of the..zones being toward one side of .the shape. In shapes which are rolled from billets cut from sections of an ingot the zones may extend entirely across the shape in such manner that' the zones are inseparable 4areas of blended laminations in the fabricated shape as is illustrated in Figure 10. By treatment of the steel in the manner and in accordance vwith the method herein disclosedonly a relatively small portion need be cut away as scrap thus a great saving is effected, and the product is improved in that the cross-sections are uniform through the length of a shape. Furthermore, the zones of iso-crystallization are uniformly distributed, thereby greatly increasing the homogeneity and strength of the iinished product.

The foregoing method primarily is intended to be practiced in conjunction with the ingot and metnod of making same disclosed in my U. S. Patent 1,327,987, Jan. 13, 1920, although it will be clear that the present method may be used to reduce the loss by scrap of such ingots as are cast in vertical molds. This is particularly true'of ingots which are cast in vertical-molds, and which ingots have one long side imperfect due to a. defective mold, lamination, cold shuts, etc., caused by metal overtlowinginto the space left between the mold and the in..

got due to mold expansion or other side flaws in the ingot. In rolling ordinary vertically cast ingots in accordance with the present invention surface improvement is more particularlythe object to be attained.

Having thus described my invention, what I claim is l. The method ofifabricating an article of 'manufacture from a steel ingot, which comprises producing an intermediate shape directly from the steel ingot without cropping the ingot and maintaining the metal of the portion of the ingot which was last to solidify-in a predetermined extended part constituting an irregular portion o f the elongated mass, separating the irregular portion from said intermediate shape as scrap and then fabricating the article from the remainl ing portion of the mass from which the scrap has been separated.

2. The method of preparing steel in an ingot for fabrication into articles of manufacture which comprises, maintaining the defective part of the ingot which formed the" top thereof in a narrow side portion of the steel mass during .the formation of an intermediate shape, and cutting away such portion as scrap from the intermediate shape before the final shapingofA the metal into the article of manufacture.

3. The method of fabricating an article of manufacture from a steel ingot which comprisesrolling the steel ingot into an intermediate shape with the deleterious portion of the ingot in a marginal fiange not intended to be a partof the nal shape, separating said {iange containing said deleterious ortion from said mass as scrap, and fabrica ing said article from the remaining portin of the mass.

4f. The method of fabricating an article from a horizontally cast steel ingot having a longitudinally extending defective surface portion, which comprises rolling the ingot in a directionsubstantially parallel to. the direction in which said defect extends compressing said defective portion in to anar- .row longitudinal extension, and subsequently and maintaining the defective-portion in a longitudinally extending marginal partof the ingotgduring such rolling, operation, and

subsequently removing the said defective portion by severing said marginal part.

6. The method of making articles of steel from an ingot having deleterious material on one side thereof, which method comprises working ,the metal into an intermediate shape and maintaining the deleterious material in an extended marginal portion of the intermediate shape; cutting away the deleterious mass; and finishing the remaining mass into av finished shape.

7. lThe method of making steel articles which comprises-rolling a horizontally cast steel ingot into an intermediate shape with the metal .comprising the top portion of the ingot being rolled into amarginal zone vand with the remaining portion of the intermediate shape comprising zones of substantiallyhomogeneous crystallization; and cutting away the marginal portionof the in# termediate shape comprising the metal from the top of the ingot.

RAY G. COATES. 

